Michael Daebritz - BDET Presentation 5th June

ING-IABSE Webinar Series in Association with IABSE-Zurich & ICE-UK
Bridge Deck Erection Technology-International Practice, Webinar lecture series from 29th May to 3rd July 2021
Movable Scaffolding Systems (MSS)

Michael Daebritz
Principal, Daebritz Baukonzept GmbH
• Born in Germany 1978

• Educated as civil engineer and welding engineer at Technical University of Dresden, Germany
• 2005-2007 and 2010-2019: concept development, sales and operation of MSS and other temporary
structures as project manager and later head of department of thyssenkrupp Infrastructure GmbH,
• 2008-2009 concept development and operation of modular formtravellers and other temporary
structures as project manager at Doka Austria
• 2019-today: Development, design and consulting for temporary structures with Daebritz
Baukonzept GmbH, based in Leipzig, Germany
Content
1. Application Range
2. General arrangement of equipment
3. Permanent work interfaces
4. Cycle times
5. Risks
6. Performance criteria
1. Application Range - Technically and economically effective operation*

Multiple span cast-in-situ bridge decks
1 stage casting 2 stage casting (trough, deck slab)
• Number of spans > 8

• Bridge length: 7…15x max. span length
• Direction of fabrication uphill (preferred) and downhill
*… The figures given are indicative for a typical MSS project, not absolute limits
1. Application Range – Technically and economically effective operation*

✓ Variable curvature radius (radius : span length ≥ 10 : 1)
✓ Variable longitudinal slope (0%...5%)
✓ Variable crossfall (-5%...+5%)
✓ Variable depth
✓ Variable span length (25m…70m)
✓ construction and deconstruction
*… The figures given are indicative for a typical MSS project, not absolute limits
2. General arrangement of equipment – typical components

Cantilever
support
Formwork Casting Launching
Formwork
cross beams
Launching nose Main girder Launching nose
Pier support Pier support

2. General arrangement of equipment – types of MSS

Overhead Underslung - typical Underslung - alongside
Cross section
Legend:
formwork frames / cross beams (for
support of the external formwork),
anchor bars,
main girders,
support and moving devices,
pier support (front support of MSS)
Complexity - + o
Weight of BDE - + (support on brackets or on towers for pier heights <15m)
Material supply - + +
Weather protection + - o
Impact on permanent work - o o
2. General arrangement of equipment – formwork

• External formwork to be opened before launching
• Weight & CoG of open formwork = relevant for stability during launching stage
• Bottom formwork in pier area
2. General arrangement of equipment – formwork
• Internal formwork with diaphragms

2. General arrangement of equipment – formwork cross beams

• Fixed on main girders
Rio Sousa (BERD) Casting Launching

2. General arrangement of equipment – formwork cross beams

• Transversely shiftable
Chomutov (thyssenkrupp Infrastructure)

2. General arrangement of equipment – precamber adjustment

a. fixed vertical setting out of formwork: for constant span lengths
b. Shimming between formwork cross beam and centering beam
c. Spindles
d. Overhead systems: HT-bars
b c d
2. General arrangement of equipment – main girders

Built up girders: Truss girders:
+ robustness regarding load introduction, + open section: easy insertion of additional parts,
torsional rigidity i.e. formwork cross beams
- wind - torsional rigidity, load introduction only in truss
joints
2. General arrangement of equipment – support & moving devices

Rolling … … Sliding … and the need for horizontal fixity of
main girders in every phase of operation
2. General arrangement of equipment – support & moving devices

• Launching and holding main girders in longitudinal direction from pier support
Mono directional function bi directional function, self-locking
Spring-
locked
teeth
cylinder
cylinders
Hollow
jack
Spring-
Spring-
locked Spring-
Winch locked
plunger locked
plunger
teeth
HT strand
2. General arrangement of equipment – pier supports

Self-propelled:
1. support for overhead MSS
2. brackets
Shifted by crane:
3. Brackets with or without struts / shear beams
4. Insert beams
5. tower 1 2
3 4 5 5
2. General arrangement of equipment – MSS rear support

• At zero-point of bending moments L/5
(cantilever support)
• Reduction of span length for MSS
• Pre-Loading of cantilever of previously cast span
• Smooth execution of deck joint
a. Suspension of underslung MSS to deck: by
HT-bars or flat iron bars
b. For overhead systems: support during
casting and launching
c. For short spans + single span systems: rear
support not at cantilever but at rear pier
d. longitudinal fixity if not at front pier
horizontal
loading with
3. Permanent work interphases small vertical
load
load
introduction deformation
points
Pier
support for
support
vertical and box-outs and
horizontal fixations
loads
Hammerhead
fixation at
overhead
systems
3. Permanent work interphases bar elongation
load on
formwork vs.
vertical load on vertical gap
deck between
formwork and
deck
Cantilever
support
transverse
box-outs in deck
horizontal load
longitudinal
horizontal load?
3. Permanent work interphases

deck weight
span length deck width
concrete formwork
placing boom
MSS weight
supports:
self-propelled
or crane-
weight deformation
during
concreting*
shifted
on-board
weather
lifting
stressing protection
equipment
equipment
on board
*main girder of a MSS can be lighter if they have continuous flexural tension members over span length, which
can be gradually stressed during concreting (patent by BERD, which is promoted as organic prestressing)

• „poor state of maintenance“ or „quality of fabrication“
• Oil leakage
• Increased friction coefficients
• Increased deformation
• Stability issues

• Pouring sequence
4. Cycle times
TYPICAL CYCLE FOR MSS: Single-cell box girder section with 60m spans
DURATION (working hours)
ACTIVITY / STEPS
8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136
Launching to next pier
- lowering of MSS
- opening of formwork cross beams
- launching
- closing of formwork cross beams
Shifting of cantilever support
- relocation
- activation
Shifting of pier supports
- dismantling in previous position
Cycle time influenced by:
- transport to nex pier
- reconfiguration and assembling
• Deck geometry
Installation of reinforcement at trough • Concrete mixture
- cleaning of formwork
- installation bottom formwork at piers • No. of pouring stages
- reinforcement not pre-fabricated
Pouring and curing of trough
• Climate
- stripping of inner wall formwork
- partial stressing
• Grade of mechanization
Installation of reinforcement at deck slab • Grade of pre-fabrication
- installation of deck formwork
- reinforcement not prefabricated • Number of shifts
Pouring and curing of deck slab
- full post-tension
• …
2-stage-pouring, crane-shifted supports 2-stage-pouring, self-propelled supports
4. Cycle times
• Project example: 10-span double T-beam
bridge with 8x regular spans of 40m length,
week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1
constant curv. radius, constant slope, single assembling MSS + formwoork in start span
shift 5 days per week production of span 1 incl. End cross beam
launching + extending to span 2
production of span 2
launching to span 3
launching to span 4
launching to span 5
launching to span 6
launching to span 7
launching to span 8
launching to span 9
launching to span 10 + shortening MSS
production of span 10 incl. End cross beam
dismantling of formwork + MSS
4. Cycle times
constant curv. radius, constant slope , single week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1
shift 5 days per week assembling MSS + formwoork in start span
launching to span 3
launching to span 4
launching to span 5
launching to span 6
launching to span 7
launching to span 8
launching to span 9
4. Cycle times
constant curv. radius, constant slope, single week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1
assembling MSS + formwoork in start span
shift 5 days per week production of span 1 incl. End cross beam
launching to span 3
launching to span 4
launching to span 5
launching to span 6
launching to span 7
launching to span 8
launching to span 9
4. Cycle times
week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1
launching to span 3
launching to span 4
launching to span 5
launching to span 6
launching to span 7
Every variation of span production of span 7
length or deck shape will launching to span 8
extend launching launching to span 9
operation due to need production of span 9
for adaptations launching to span 10 + shortening MSS
4. Cycle times
week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
production of span 1 incl. End cross beam 33% Assembling 39% Regular cycles 28% last span +
+ 1st span dismantling
launching to span 3
launching to span 4
launching to span 5
launching to span 6
launching to span 7
Effect of training:
launching to span 8 Optimization of cycle times
launching to span 9
5. Risks - Operation
Operation stage Risk of accident Risk of damage to permanent works
Launching / Adaptations
Pouring
5. Risks – Operation - supports

Fixity of supports:
• in casting stage: vertical pressure,
balanced in transverse direction
• In launching stage: excentric loading
In picture:
5,5% uphill
5,0% cross fall, 650m radius
50m pier height
50m span length
3,4m transverse distance of insert beams
Width of pier cross beams: 20m
5. Risks – Operation – hydraulics (1)

Sudden change of hydraulic pressure in launching:
✓Stop operation
✓Check source of problem
✓Remove obstacle / Repair
5. Risks – Operation – hydraulics (2)

Reading of manometers ist vitally important.
Do not underestimate the power of hydraulic systems:

Stressing of cantilever suspension → risk of formwork damage
lowering of MSS: push up carefully to open locknut of support jacks →
risk of damaging formwork and MSS
5. Risks – Operation - weather

Snow and water can cause extra loads
Wind: storm protection, launching
Weather forecast must be checked before

opening formwork.
5. Risks – Operation – human factor

• Communication on site (large convoluted piece of
metal to be operated by a coordinated team)
• Assembling and operation team should be
qualified to understand AND predict the reactions
of MSS and bridge on their actions
• Assembling and operation team should not be
changed during a project
• Monotonous launching operation can lead to lack
of attention
• Repeat safety instructions and point out critical
actions each time before launching
→ Take care of yourself and your colleagues!
5. Risks
Activity Risk Mitigating measures
1st assembling or dismantling • Indicate CoG (centre of gravity) in all adaptation /
Launching moving phases in longitudinal and transversal
overturning of MSS due to loss of control of longitudinal
direction
movement → loss of equilibrium → overturning of MSS's
Self-relocation of supports supports and loss of entire gantry • Periodically counter-check CoG
• Back up fixity, nominal tie down of supports,
presence of MSS engineer and gantry supervisor
• Check resistance of pier and strengthen if pier
required against horizontal loads with real friction
and launching forces
Launching on pier overturning of permanent structure • Limit maximum launching force to match pier’s
capacity
• Control or prevent displacement of pier in launching
stage
5. Risks
overturning of MSS due to failure of MSS support • 3rd party check after each assembling of support
• Match load dimensions and introduction points with
pier and deck design within geometrical tolerances
given by the engineer in charge of structural checks
of the construction stages
Pouring stage • Stress tie down bars to at least SLS level (as defined
overturning of MSS due to failure of permanent
by engineer). Verify locked in forces (use of
structure
calibrated pressure gauges)
• Adequate edge distances, so that support's contact
area is within concrete confined by reinforcement;
shimming with similar material over entire foot print
of support's contact area
Opening / Closing of Provision of stairs and access platforms with handrails
Longitudinal and vertical access and work at height,
formwork’s cross beams for and kicker boards;
falling objects
launching stage No traffic underneath MSS
5. Risks
Man-lift for all assembling operations, access stair case,
Shifting of pier supports Falling down of people or materials from >3m of height
safety line fixed to pier
Damage of formwork in pier and cantilever joint area
Pouring stage Permanent survey of support forces during pouring
due to overloading
Working on top of and inside
Provision of handrails (or at least safety lines) around all
of bridge deck
Danger to workers when at height exposed edges on top and inside of MSS / bridge deck
Working on top of and inside
installed prior to launching of MSS
of MSS
Free hanging hanger bars Bars may turn out of couplers/nuts and subsequently fall Do not leave single hanger bars suspended unloaded, or
exposed to wind down due to wind induced oscillation about bars' vertical provision of locking pins/nuts. Mark the bars
axis
6. Performance Criteria
Flexible, highly adaptive construction method, influenced by:
• Bridge and surroundings:
→Geometry of deck and substructure
→Post tensioning layout
→Concrete mixture, curing time
→Alignment of bridge
→surroundings of bridge: available infrastructure
→Access to piers etc.
→Positions of supports
→Environmental aspects
• Expectations to construction:
→Formwork
→Fabrication specs:
→1 stage or 2 stage concreting
→Material supply and degree of prefabrication
(reinforcement)
→Follow-up works (closing of box-outs, touch up etc.)
→completion works (parapets, drainage etc.) can start before end
of construction of bridge deck
• Performance level of BDE:
→Material supply to MSS
→Degree of prefabrication of rebars etc.
→Degree of mechanization, i.e. regarding adjustment of
precamber
→Cycle times
→Assembling & operation team
→Longitudinal launching speed alone is not a winning

point
• Project characteristics:
→Project schedule
→Architectural features
→Shipment costs
→Reusability
→Availability and costs of lifting equipment in
comparison to costs of manpower
7. End of presentation
I am looking forward to discussing with you during the panel

discussion.
In case of further questions, please contact

info@dbk-ost.de

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ING-IABSE Webinar Series in Association with IABSE-Zurich & ICE-UK

Movable Scaffolding Systems (MSS)

• Born in Germany 1978

1. Application Range - Technically and economically effective operation*

• Number of spans > 8

1. Application Range – Technically and economically effective operation*

2. General arrangement of equipment – typical components

Formwork Casting Launching

Launching nose Main girder Launching nose

Pier support Pier support

2. General arrangement of equipment – types of MSS

2. General arrangement of equipment – formwork

2. General arrangement of equipment – formwork

• Internal formwork with diaphragms

2. General arrangement of equipment – formwork cross beams

Rio Sousa (BERD) Casting Launching

2. General arrangement of equipment – formwork cross beams

Chomutov (thyssenkrupp Infrastructure)

2. General arrangement of equipment – precamber adjustment

2. General arrangement of equipment – main girders

2. General arrangement of equipment – support & moving devices

2. General arrangement of equipment – support & moving devices

2. General arrangement of equipment – pier supports

2. General arrangement of equipment – MSS rear support

3. Permanent work interphases bar elongation

3. Permanent work interphases

span length deck width

3. Permanent work interphases

3. Permanent work interphases

Operation stage Risk of accident Risk of damage to permanent works

5. Risks – Operation - supports

5. Risks – Operation – hydraulics (1)

5. Risks – Operation – hydraulics (2)

Do not underestimate the power of hydraulic systems:

5. Risks – Operation - weather

Weather forecast must be checked before

5. Risks – Operation – human factor

→Longitudinal launching speed alone is not a winning

I am looking forward to discussing with you during the panel

In case of further questions, please contact

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